Electrical switchboard apparatus with center fed vertical riser bus

ABSTRACT

An electrical distribution switchboard including a multiphase horizontal main bus and a multiphase vertical riser bus. A plurality of tie members are provided, one tie member being connected to each vertical phase member. Each horizontal phase conductor is connected to the tie member of its corresponding vertical phase conductor so as to symmetrically locate the top and bottom of each tie member above and below the horizontal centerline of the horizontal main bus, allowing the vertical riser bus to be fed at its electrical and geometric center.

This is a continuation of application Ser. No. 913,154, filed Jun. 6,1978, now abandoned, which is a division of Ser. No. 755,705, filed Dec.30, 1976.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present invention is related to copending U.S. Pat. applicationsSer. No. 756,035, now U.S. Pat. No. 4,099,220 entitled "ElectricalSwitchboard Apparatus Including Welded Bus Connector" filed Dec. 30,1976, by G. N. Kovatch, R. Rosey, and N. H. Simon; Ser. No. 756,036, nowU.S. Pat. No. 4,136,374 entitled "Electrical Switchboard ApparatusIncluding Double Flanged Vertical Riser Conductors" filed Dec. 30, 1976,by G. N. Kovatch, R. Rosey, N. H. Simon, and N. A. Tomasic; and Ser. No.755,540, now U.S. Pat. No. 4,118,639 entitled "Electrical SwitchboardApparatus Including Bus System With Individual Phase Isolation" filedDec. 30, 1976, by G. N. Kovatch, R. Rosey, and N. H. Simon. All of theabove-mentioned copending U.S. patent applications are assigned to theassignee of the present invention.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to electrical switchboard apparatus and moreparticularly to means for connecting the main horizontal bus to thevertical riser bus forming a part of such switchboard apparatus.

2. Description of the Prior Art

An electrical distribution switchboard distributes the main incomingpower among various site functions such as heating, lighting, and airconditioning. It typically consists of a number of vertical cabinetsections containing circuit breakers for switching and protecting thevarious load circuits. Three-phase electrical power enters a switchboardvia cable or bus duct connected to a main bus which runs horizontallywithin the switchboard between the various sections. The main bus isconnected to vertical, or riser, bus in each vertical cabinet section.Various circuit interrupters stacked vertically in the cabinet sectionshave their inputs connected to the vertical riser bus and their outputsconnected to horizontal load side extensions which run toward the rearof the cabinet perpendicular to the main horizontal bus. Bus duct orcable is then attached to the load side extensions to permit the powerto exit the switchboard and flow to the load (air conditioning,lighting, motors, etc.).

The primary requirements for a switchboard are that it be safe anddependable, and that it exhibit low cost in construction, installation,and maintenance. In addition, the switchboard should be of compactconstruction to reduce space requirements at the user location. Thedesign of the switchboard should include sufficient versatility to allowcircuit breakers of various interruption capacities and frame sizes tobe easily included in the switchboard.

Specifically, it would be desirable to provide an electrical switchboardwith the capacity to stack six 800 amp breakers in a single verticalsection while providing the capability to include other frame sizes in asingle section, such as four 1600 amp breakers, two 3000 amp breakers,or combinations of different frame size breakers within the samevertical section. Prior art electrical switchboards often required threedifferent positions for the main horizontal bus, depending upon thebreaker frame size mix. This required additional engineering designeffort to specify the location of the horizontal bus for each individualapplication, as well as the need for more complex installationprocedures. It would be desirable to provide a switchboard having asingle location for the main horizontal bus for all breaker frame sizemixes.

In producing a cost effective switchboard design, some objections areoften in conflict. For example, it is possible to produce a designutilizing a minimum of material but this often dictates the necessityfor a large number of different parts to accommodate the wide variety ofindividual switchboard applications. It would therefore be desirable toprovide an electrical switchboard requiring a minimum amount of materialand a minimum number of component styles, yet which is easily adaptableto accommodate a large variety of individual applications.

In order to provide such flexibility, it is desirable to have individualcomponent parts perform more than one function. For example, severalsmall lengths of vertical riser bus could be combined to form a varietyof total riser bus lengths. By feeding the vertical riser bus at thegeometric center, it would be possible to use a single part for both theupper and lower riser bus section.

In addition, it would be desirable to provide a uniform cross-section ofvertical riser bus throughout its length. One method of achieving wouldbe to feed the vertical bus in its electrical center. For example, ifsix 800 amp breakers are stacked in a single vertical section, the totalamount of current which can be carried by these circuit breakers is6×800=4,800 amperes. However, if the associated vertical riser bus isconnected to the horizontal main bus at a point midway between the topand bottom circuit breakers, e.g. the electrical center of the verticalriser bus, the amount of current which is required to be carried by anyone portion of the vertical riser bus is only one half of the totalcapacity of the section, since half the current will flow upward intothe three upper circuit breakers and half will flow downward into thethree lower circuit breakers. Therefore, the total current carryingrequirement of any portion of the vertical riser bus is only 3×800=2,400amperes. It would therefore be desirable to provide an electricalswitchboard having the vertical riser bus connected to the mainhorizontal bus so as to feed the vertical riser bus at its geometric andelectrical center.

SUMMARY OF THE INVENTION

In accordance with a preferred embodiment of the present invention,there is provided an electrical power distribution switchboardcomprising a cabinet structure, and a multiphase horizontal main busdisposed within the cabinet structure and having individual horizontalphase conductors vertically spaced one above the other. The switchboardalso includes a multiphase vertical riser bus disposed within thecabinet structure and having the individual vertical phase conductorshorizontally spaced one beside the other. A plurality of tie members areprovided, each tie member being connected to one vertical phaseconductor. Each horizontal phase conductor is connected to the tiemember of its associated vertical phase conductor so as to symmetricallylocate the top and bottom of each tie member respectively above andbelow the horizontal centerline of the horizontal main bus. The tiemember thus becomes an extension of the horizontal main bus in thevertical direction.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the invention, reference may be had to thepreferred embodiment exemplary of the invention shown in theaccompanying drawings, in which:

FIG. 1 is a perspective view of a four-section electrical powerdistribution switchboard;

FIG. 2 is a diagrammatic view of an electrical switchboard employing theprinciples of the present invention, showing the locations of load andline connectors for a variety of circuit breaker frame sizes;

FIG. 3 is a side view of one section of the switchboard of FIG. 1;

FIG. 4 is a diagrammatic view of the horizontal main bus of thefour-section switchboard of FIG. 1;

FIG. 5 is a perspective view of the junction between the horizontal mainbus and the vertical riser bus of a single section of the switchboard ofFIG. 1;

FIG. 6A is a detail sectional view of the switchboard section of FIG. 5,taken along the line A--A of FIG. 5;

FIG. 6B is a sectional view similar to FIG. 6A taken along the line B--Bof FIG. 5;

FIG. 7A is a side view of a phase A vertical phase conductor;

FIG. 7B is a side view of a phase B vertical phase conductor;

FIG. 7C is a side view of phase C vertical phase conductor;

FIG. 7D is an end view of any of the vertical phase conductors shown inFIGS. 7A-7C;

FIG. 8 is a detail perspective view of one phase of the bus junctionshown in FIG. 5;

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings, in which like reference characters referto like components, FIG. 1 shows an electrical distribution switchboard10 having four vertical section structures 12, 14, 16, and 18. Each ofthe sections of the switchboard 10 includes a device compartment 20separated into cells 22, a bus compartment 24, and a cable compartment26. Each of the cells 22 contains circuit interrupters or instrumentsused in controlling or monitoring electrical circuits powering loadssuch as air conditioners, motors, and lighting.

Generally, each of the vertical sections 12, 14, 16, 18 comprisestructural members such as 28 and 30 to which cover sheets 32 and doors34 are added. Circuit breaker controls and indicators 35 are accessablethrough the doors 34 to operate and indicate the status of the enclosedcircuit breakers.

Incoming main power is connected to a main bus which runs horizontallythrough the bus compartments 24 of the board 10 connecting the sections12, 14, 16, 18. The circuit breakers in each section are then connectedto the horizontal bus thrugh riser bus extending vertically in the buscompartments of each of the sections 12, 14, 16, 18.

As can be seen in FIGS. 3, 6A, and 6B, each of the circuit breakers 23includes movable sliding contact connectors, or finger assemblies, 37cooperating with line stab connectors 36 and load stab connectors 38.The interaction of the fixed stabs 36, 38 and the movable fingerassemblies 37 provides sliding contact connection allowing the circuitbreakers to be inserted and withdrawn from the cells 22. Other meansproviding such sliding contact connection could, of course, be used. Theline stabs 36 which are connected to the vertical riser bus supplyincoming power to the separable contacts within the circuit breaker,from which the power then flows outward through the load stabs 38 andload side runbacks 72 to the distribution circuits and loads which willultimately be supplied.

As can be seen in FIG. 3, a variety of circuit breaker frame sizes mustbe provided for. It is desirable to design the bus structure to becompatible with such a variety and mix of circuit breaker frame sizeswhile at the same time utilizing a minimum amount of material andsimplifying, the installation of the switchboard. Prior art switchboardsoften provided for three different locations for the horizontal bus: atthe top, the center, and the bottom of the switchboard, the location ofthe horizontal bus being dependent upon the location and frame size mixof the circuit breakers to be included in each individual switchboardand, specifically, the location of the load side connection. The loadside runbacks extend back through the bus compartment and into the cablecompartment, complicating the bus layout, since required insulationclearances must be maintained. FIG. 2 (a diagram not related to thespecific circuit breaker configuration of FIG. 1) shows the locations ofthe line and load side stab connectors 36 and 38 for three differentcircuit breaker frame sizes, 3,000 ampere, 1,600 ampere, and 800 ampere,and the respective breaker horizontal centerlines 40, 42, and 44. Thehatched rectangles indicate the location of load stabs 38. Above thehorizontal centerline 58 of the switchboard are conventional circuitbreakers which are bottom fed, that is, circuit breakers with the inputline side stabs 36 at the bottom and the output load side connections 38at the top. By employing these normal circuit breakers above thehorizontal centerline of the vertical section structure and by usingtop, or reverse, fed circuit breakers below the horizontal buscenterline, it can be seen that an area around the horizontal centerlinebecomes free of load side connectors 38 and runbacks 72. This thenbecomes the ideal position to locate the three phase conductors of thehorizontal bus 46.

It is also desirable to reduce the amount of material employed in thehorizontal bus structure. FIG. 4 shows a diagrammatic rear view of thehorizontal bus structure of the switchboard of FIG. 1. As can be seen,three conductor members 47 of horizontal bus 46 supply the four verticalstructures 12, 14, 16, 18, with each section being connected at eitherend to corresponding vertical individual phase conductors of adjacentriser bus sections. Splice points are indicated by X's on FIG. 4 andoccur at the point of connection between corresponding individual phaseconductors of the horizontal and vertical bus. By using such connectionsinstead of structure width conductor members spliced at structureboundaries, considerable savings in material can be realized.

In order to minimize the number of different parts required for avariety of switchboard combinations, and to minimize the requiredcross-section of the vertical riser bus, it is desirable to supply powerto the vertical riser bus at its geometric and its electrical center.This is accomplished in the present invention through the use of a tiemember, or tie maker bar 52, as is shown in FIG. 5, a perspective viewof the bus junction of section 16 of the switchboard of FIG. 1. Variousparts have been omitted from FIG. 5 in order to more clearly indicatethe method of connecting the vertical and horizontal bus. The tie makerbar 52 is a generally rectangularly sectioned aluminum extrusion havingchamfered edges 47 (FIG. 7D) to facilitate welding to I-beams 54 and aconnector block 50.

As can be seen most clearly in FIG. 8, each individual phase conductor47 of the main horizontal bus 46 comprises four spaced parallel aluminumbars 48 welded through the connector block 50 to the tie maker bar 52which is in turn welded to a pair of I-beams 54 to form an individualphase conductor 57 of the vertical riser bus 56. The two I-beams 54 eachhave front and rear flanges connected by a web portion and aresymmetrically disposed on either side of the centerline 58 of the mainhorizontal bus 46. Similarly, each tie maker bar 52 of each phaseconductor 57 of the vertical riser bus 56 is similarly disposed with itstop and bottom symmetrically located above and below the horizontal mainbus centerline 58 and approximately even with the upper edge of theupper horizontal phase conductor and the lower edge of the lowerhorizontal phase conductors, respectively. The connector 50 of phase Ais seen to be welded to the top portion of its associated tie maker bar52, while the connector 50 of phase C is welded to the lower portion ofits associated tie maker bar 52. The phase B connector is welded to thecenter of its associated tie maker bar. This can be seen more clearly inFIGS. 7A through 7C, which are side views of the vertical phaseconductors of phases A, B, and C, respectively.

The length of the tie maker bar 52 is determined by the amount ofavailable contact area between it and the I-beams, 54 which is in turndetermined by the weld bead area. In all cases, however, maximumbenefits are obtained where the tie maker bar 52 is locatedapproximately symmetrical with respect to the horizontal bus centerline59.

As can be seen in FIG. 5, three 800 ampere circuit breakers, mountedabove the centerline 58 of the horizontal main bus 46, are bottom-fedthrough the upper I-beams 54 of the associated vertical riser bus 56,and through tie maker bars 52 to the horizontal main bus 46. Similarly,the lower three circuit breaker connections are connected to the mainhorizontal bus below the centerline 58 through the bottom I-beams of theassociated vertical riser bus 56 and are top-fed. The disclosedconstruction employing a tie maker bar 52 allows each vertical phaseconductor 57 to be fed at its electrical and its geometric center. Thisallows a single extrusion to be used interchangeably as either the upperhalf of the vertical phase conductor 57 or the lower half. Similarly, noI-beam 54 is required to carry more than half of the total current whichcould be supplied through the associated vertical section structure. Ofcourse, for some section configurations it is not necessary to use afull length of I-beam, such as when only a single breaker is to bemounted in the top or bottom half of a section. The two I-beams may alsobe welded together in certain applications.

The construction of the connector block 50 is shown most clearly inFIGS. 5, 6, 7A-7D, and 8. The connector block 50 is formed from agenerally rectangularly cross-sectioned aluminum extrusion with aplurality of locating means such as the rectangularly sectionedchannels, or grooves, 53 formed laterally along the largest side surfaceof the connector block 50. The top and bottom I-beams 54, the tie makerbar 52, and the connector 50 are assembled at a bench location to formeach vertical phase conductor 57 of the vertical riser bus 56. Each ofthe three vertical phase conductors 57 for each vertical sectionstructure is mounted (in the manner to be hereinafter described) to aglass polyester insulating barrier 62 disposed between the devicecompartment 20 and the bus compartment 24. The horizontal bars 48 arethen welded to the connector 50 in the grooves 53 beginning with thegroove closest to the tie maker bar 52. The remaining bars 48 are thenwelded one by one between the connecting blocks 50 of the correspondingphases of adjacent vertical structures. The connector block 50 allowsthe horizontal bars 48 to be easily located in the proper positionduring assembly, thereby maintaining the desired spacing between bars.This spacing is provided to reduce the amount of material necessary fora given current carrying capacity of the main horizontal bus, since ithas been found that a plurality of parallel spaced conductors is moreefficient than a single conductor of the same cross-sectional area. Nojig fixture is required to hold all bars in position prior to weldingsince the bars are positioned one at a time rather than requiring two ormore bars to be welded together. In certain cases where maximum currentcarrying capacity is not required, one or more grooves can be leftblank, thereby increasing the spacing between the remaining bars.Tapering of the main horizontal bus is also easily accomplished with thegrooved connector 50 by bringing the desired number of bars into theconnector 50 on one side and attaching a fewer number of bars on theopposite side, downstream from the power source.

The main horizontal bus 46 is entirely supported by the vertical riserbus 56. Thus, the main horizontal bus can be composed of conductingmembers equal in length to the spacing between like phases of adjacentvertical riser bus, with mechanical and electrical connections beingmade only at the ends of the members. This saves considerable materialover the section width bus system, as is shown in FIG. 4.

It is not necessary for the connector blocks 50 to have a rectangularcross-section. For example, the sides could converge in steps, with thewidest step at the point where the connector block 50 is welded to thetie maker bar 52 and the narrowest step at the top of the block farthestfrom the tie maker bar 52, thereby forming a "Christmas tree"cross-section. While the benefits obtainable through the use of the tiemaker bar are not limited to bus systems employing the grooved connector50, it has been found that increased versatility and reduced assemblycost result from the use of the connector block 50 as shown anddisclosed herein.

Similarly, it is not necessary to employ the tie maker bar constructionin order to obtain the benefits provided by the grooved connector block50. However, the tie maker bar provides a simple and effective means forfeeding the vertical riser bus at its geometric and electrical center.These same tie maker bar benefits are also obtained when used in boltedsystems.

The insulating glass polyester barrier 62 separates the devicecompartment 20 and the bus compartment 24. The I-beams 54 of thevertical riser bus 56 are mounted to the glass polyester barrier bybolts 64 passing through the barrier 62 from the device compartment sidethereof. The bolts 64 are threaded into fluted press nuts 65 insertedfrom the rear into holes in the front flange of the I-beams 54. As thebolts 64 are tightened, the I-beams 54 are secured to the polyesterbarrier 62.

The line stab connectors 36 for the circuit breakers 23 are similarlyfastened to the front flange of the I-beams 54 with bolts and press nuts65, while the load stab connectors are bolted to the barrier 62 usingthreaded inserts 67 (FIG. 6B). The connectors 36 and 38 extend throughholes in the glass polyester barrier 62 into the device compartment 20.Metering current transformers 66 are mounted upon the connectors 36 and38 from the device compartment side of the polyester barrier 62. Sincethe press nuts are fixed into the flange of the I-beams 54, and thethreaded inserts 67 are fixed in the polyester barrier 62, access to thepress nuts and threaded inserts is not required when inserting orremoving the bolts. Thus, the connectors 36 and 38 can be removed orreplaced from the device compartment 20 of the switchboard, eliminatingthe need to deenergize the switchboard and gain access to the buscompartment 24. Since the current transformers 66 are mounted upon theconnectors 36 and 38 on the device compartment side of the polyesterbarrier 62, they can be similarly replaced without requiring access tothe bus compartment. This is an important maintenance and safety featuresince it is not required to remove any of the cover sheets 32 to replacecurrent transformers or line connectors, nor is it necessary to subjectthe users of the switchboard to a service interruption fordeenergization, as was sometimes required in prior art switchboards.

The rear flange of the I-beams 54 secures riser support members 68,providing needed structural strength to resist forces produced undertransient overload current situations. Similarly, members 70 areprovided to support the load side runbacks 72 which extend rearwardlyinto the cable compartment 26 for connection to outgoing cables or busduct. The members 70 are bolted to the riser bus and bus compartmentstructure, as seen in FIGS. 6A and 6B, and include notches, or cutouts,through which the load side runback extends. These notches providelateral rigidity and prevent side-to-side movement of the load siderunbacks 72 caused by electromagnetic forces under severe overcurrentconditions.

It can be seen therefore, that the I-shaped cross-section of thevertical riser bus 56 provides an efficient means for mechanical supportof the vertical riser bus 56 and associated members while providing ahigh electrical current carrying capacity in a compact configuration.

What is claimed is:
 1. Electrical power distribution bus apparatuscomprising:a main supply bus connected to a source of electrical powercomprising a plurality of main supply bus phase conductors disposed in acommon plane; a distribution bus connected to an electrical load, saiddistribution bus comprising a like number of distribution bus phaseconductors substantially perpendicular to said main supply bus phaseconductors and parallel to the plane defined by said main supply busphase conductors; and a plurality of elongated electrically conductivetie members each connected between one of said main supply bus phaseconductors and a corresponding distribution bus phase conductor, each ofsaid elongated tie members being symmetrically positioned with respectto the longitudinal centerline of said main supply bus and extendingparallel to its corresponding distribution bus phase conductor and beingin electrical contact with said distribution bus phase conductor atpoints along the length of said elongated tie member.
 2. Apparatus asrecited in claim 1 wherein each of said elongated tie members includes aplurality of surfaces parallel to its longitudinal axis, one of saidsurfaces being electrically joined to said corresponding main supply busphase conductor and another of said surfaces being electrically joinedto said corresponding distribution bus phase conductor.
 3. Apparatus asrecited in claim 2 wherein each of said distribution bus phaseconductors extends in opposite directions away from its correspondingmain supply bus phase conductor.
 4. Apparatus as recited in claim 3wherein each of said distribution bus conductors comprises first andsecond separate portions each extending in opposite directions from saidcorresponding main supply bus phase conductor.
 5. Apparatus as recitedin claim 4 wherein said first and second distribution bus conductorportions are electrically joined to their corresponding tie member atpoints symmetrically located on opposite sides of the longitudinalcenterline of said main supply bus.
 6. Apparatus as recited in claim 2wherein said joined tie member surfaces are substantially parallel. 7.Apparatus as recited in claim 6 wherein each of said tie members has asubstantially rectangular cross section.
 8. Apparatus as recited inclaim 7 wherein each of said tie members has chamfered longitudinaledges.
 9. Electrical power distribution bus apparatus comprising:a mainsupply bus connected to a source of electrical power comprising aplurality of main supply bus phase conductors disposed in a commonplane; a distribution bus connected to an electrical load, saiddistribution bus comprising a like number of distribution bus phaseconductors substantially perpendicular to said main supply bus phaseconductors and parallel to the plane defined by said main supply busphase conductors; and a plurality of elongated electrically conductivetie members each connected between one of said main supply bus phaseconductors and a corresponding distribution bus phase conductor, each ofsaid elongated tie members being symmetrically positioned with respectto the longitudinal centerline of said main supply bus and extendingparallel along its entire length to its corresponding distribution busphase conductor and being in electrical contact with said distributionbus phase conductor at points along the length of said elongated tiemember.
 10. Apparatus as recited in claim 9 wherein each of saidelongated tie members includes a plurality of surfaces parallel to itslongitudinal axis, one of said surfaces being electrically joined tosaid corresponding main supply bus phase conductor and another of saidsurfaces being electrically joined to said corresponding distributionbus phase conductor.
 11. Apparatus as recited in claim 9 wherein each ofsaid distribution bus phase conductors extends in opposite directionsaway from its corresponding main supply bus phase conductor. 12.Apparatus as recited in claim 9 wherein each of said distribution busconductors comprises first and second separate portions each extendingin opposite directions from said corresponding main supply bus phaseconductor.
 13. Apparatus as recited in claim 9 wherein said first andsecond distribution bus conductor portions are electrically joined totheir corresponding tie member at points symmetrically located onopposite sides of the longitudinal centerline of said main supply bus.14. Apparatus as recited in claim 9 wherein said joined tie membersurfaces are substantially parallel.
 15. Apparatus as recited in claim 9wherein each of said tie members has a substantially rectangular crosssection.
 16. Apparatus as recited in claim 9 wherein each of said tiemembers has chamfered longitudinal edges.